Welding training systems and devices

ABSTRACT

A welding tool includes a first handle and a second handle. The welding tool also includes a torch nozzle holder configured to hold a nozzle of a welding torch therein, and to block the nozzle from extending therethrough. The welding tool includes a blade assembly positioned a predetermined distance from the torch nozzle holder. The blade assembly is configured to cut welding wire extending through the blade assembly to calibrate wire stickout from the welding torch to the predetermined distance.

BACKGROUND

The invention relates generally to welding and, more particularly, to awelding training system.

Welding is a process that has increasingly become utilized in variousindustries and applications. Such processes may be automated in certaincontexts, although a large number of applications continue to exist formanual welding operations. In both cases, such welding operations relyon a variety of types of equipment to ensure the supply of weldingconsumables (e.g., wire feed, shielding gas, etc.) is provided to theweld in appropriate amounts at the desired time.

In preparation for performing manual welding operations, weldingoperators may be trained using a welding training system. The weldingtraining system may be designed to train welding operators with theproper techniques for performing various welding operations. Certainwelding training systems may use various training methods. As may beappreciated, these training systems may be expensive to acquire andoperate. Accordingly, welding training institutions may only acquire alimited number of such training systems. Furthermore, certain weldingtraining systems may not adequately train welding operators to performhigh quality welds.

BRIEF DESCRIPTION

In one embodiment, a welding tool includes a first handle and a secondhandle. The welding tool also includes a torch nozzle holder configuredto hold a nozzle of a welding torch therein, and to block the nozzlefrom extending therethrough. The welding tool includes a blade assemblypositioned a predetermined distance from the torch nozzle holder. Theblade assembly is configured to cut welding wire extending through theblade assembly to calibrate wire stickout from the welding torch to thepredetermined distance.

In another embodiment, a method for calibrating wire stickout from awelding torch includes adjusting a welding wire stickout calibrationtool for a selected welding wire length. The method also includesinserting a welding torch into the welding wire stickout calibrationtool, such that a nozzle of the welding torch abuts a torch nozzleholder of the welding wire stickout calibration tool. The methodincludes actuating a trigger of the welding torch to extend a weldingwire from the welding torch through a blade assembly of the welding wirestickout calibration tool. The method also includes compressing handlesof the welding wire stickout calibration tool to cut the welding wireextending through the blade assembly in the welding wire stickoutcalibration tool.

In another embodiment, a welding consumable includes a first physicalmark indicating a first location on the welding consumable. The weldingconsumable also includes a second physical mark indicating a secondlocation on the welding consumable. The first physical mark and thesecond physical mark are configured to be detected by a camera-baseddetection system to determine a remaining length of the weldingconsumable, a consumed length of the welding consumable, a rate of useof the welding consumable, a dipping rate of the welding consumable, orsome combination thereof.

In a further embodiment, a welding training system includes acamera-based detection system and a welding consumable. The weldingconsumable includes a first physical mark indicating a first location onthe welding consumable and a second physical mark indicating a secondlocation on the welding consumable. The first physical mark and thesecond physical mark are configured to be detected by the camera-baseddetection system to determine a remaining length of the weldingconsumable, a consumed length of the welding consumable, a rate of useof the welding consumable, a dipping rate of the welding consumable, orsome combination thereof.

In a further embodiment, a welding training system includes a weldingsurface and a sensor configured to sense a position of a welding torch,an orientation of the welding torch, or some combination thereof. Thewelding training system also includes a first arm coupled to the weldingsurface, and extending vertically from the welding surface. The weldingtraining system includes a pivot assembly coupled to the first arm andto the sensor. The pivot assembly enables adjustment of an angle betweenthe first arm and the sensor.

DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a block diagram of an embodiment of a welding training systemin accordance with aspects of the present disclosure;

FIG. 2 is a block diagram of an embodiment of portions of the weldingtraining system of FIG. 1 in accordance with aspects of the presentdisclosure;

FIG. 2A is a schematic diagram of an embodiment of circuitry of thewelding torch of FIG. 1 in accordance with aspects of the presentdisclosure;

FIG. 3 is a perspective view of an embodiment of the welding torch ofFIG. 1 in accordance with aspects of the present disclosure;

FIG. 4 is a perspective view of an embodiment of the training stand ofFIG. 1 in accordance with aspects of the present disclosure;

FIG. 5 is a perspective view of an embodiment of a calibration device inaccordance with aspects of the present disclosure;

FIG. 6 is a perspective view of an embodiment of a fixture assembly inaccordance with aspects of the present disclosure;

FIG. 7 is a perspective view of a welding wire stickout calibration toolin accordance with aspects of the present disclosure;

FIG. 8 is a top view of the welding wire stickout calibration tool ofFIG. 7 in accordance with aspects of the present disclosure;

FIG. 9 is an embodiment of a method for calibrating wire stickout from awelding torch in accordance with aspects of the present disclosure;

FIG. 10 is a perspective view of an embodiment of a welding consumablehaving physical marks in accordance with aspects of the presentdisclosure;

FIG. 11 is a perspective view of an embodiment of welding wire havingphysical marks in accordance with aspects of the present disclosure;

FIG. 12 is a perspective view of an embodiment of a vertical armassembly of the training stand of FIG. 1 in accordance with aspects ofthe present disclosure;

FIG. 13 is a perspective view of an embodiment of an overhead weldingarm assembly in accordance with aspects of the present disclosure;

FIG. 14 is a block diagram of an embodiment of welding training softwarehaving multiple training modes in accordance with aspects of the presentdisclosure;

FIG. 15 is a block diagram of an embodiment of a virtually reality modeof welding training software in accordance with aspects of the presentdisclosure;

FIG. 16 is an embodiment of a method for integrating training resultsdata in accordance with aspects of the present disclosure;

FIG. 17 is an embodiment of a chart illustrating multiple sets ofwelding training data for a welding operator in accordance with aspectsof the present disclosure;

FIG. 18 is an embodiment of a chart illustrating welding training datafor a welder compared to welding training data for a class in accordancewith aspects of the present disclosure;

FIG. 19 is a block diagram of an embodiment of a data storage system forstoring certification status data in accordance with aspects of thepresent disclosure;

FIG. 20 is an embodiment of a screen illustrating data corresponding toa training weld in accordance with aspects of the present disclosure;

FIG. 21 is an embodiment of a screen illustrating a discontinuityanalysis of a training weld in accordance with aspects of the presentdisclosure;

FIG. 22 is a block diagram of an embodiment of a welding instructorscreen of welding training software in accordance with aspects of thepresent disclosure;

FIG. 23 is an embodiment of a method for weld training using augmentedreality in accordance with aspects of the present disclosure; and

FIG. 24 is an embodiment of another method for weld training usingaugmented reality in accordance with aspects of the present disclosure.

DETAILED DESCRIPTION

FIG. 1 is a block diagram of an embodiment of a welding training system10. The welding training system 10 includes a training stand 12 forproviding support for various training devices. For example, thetraining stand 12 may be configured to support a welding surface, aworkpiece, a fixture, one or more training arms, and so forth. Thewelding training system 10 also includes a welding torch 14 that may beused by a welding operator (e.g., welding student) to perform trainingoperations. As described in greater detail below, the welding torch 14may be configured with a user interface configured to receive inputsfrom the welding operator, control circuitry configured to process theinputs, and a communication interface configured to provide the inputsto another device. Furthermore, the welding torch 14 may include one ormore display and/or indicators to provide data to the welding operator.Moreover, the welding training system 10 includes a sensing device 16(e.g., sensor, sensing assembly, and so forth) used to sense a positionof one or more welding devices and/or to sense an orientation of one ormore welding devices. For example, the sensing device 16 may be used tosense a position and/or an orientation of the training stand 12, thewelding torch 14, a welding surface, a workpiece, a fixture, one or moretraining arms, and so forth. The sensing device 16 may include anysuitable sensing device, such as a motion sensing device or a motiontracking device. Furthermore, the sensing device 16 may include one ormore cameras, such as one or more infrared cameras, one or more visiblespectrum cameras, one or more high dynamic range (HDR) cameras, and soforth.

The sensing device 16 is communicatively coupled to a computer 18. Thesensing device 16 is configured to provide data (e.g., image data,sensed data, six degrees of freedom (6DOF) data, etc.) to the computer18. Furthermore, the sensing device 16 may be configured to receive data(e.g., configuration data, setup data, commands, register settings,etc.) from the computer 18. The computer 18 includes one or moreprocessors 20, memory devices 22, and storage devices 24. Theprocessor(s) 20 may be used to execute software, such as weldingtraining software, image processing software, sensing device software,and so forth. Moreover, the processor(s) 20 may include one or moremicroprocessors, such as one or more “general-purpose” microprocessors,one or more special-purpose microprocessors and/or application specificintegrated circuits (ASICS), or some combination thereof. For example,the processor(s) 20 may include one or more reduced instruction set(RISC) processors.

The storage device(s) 24 (e.g., nonvolatile storage) may include ROM,flash memory, a hard drive, or any other suitable optical, magnetic, orsolid-state storage medium, or a combination thereof. The storagedevice(s) 24 may store data (e.g., data corresponding to a trainingoperation, video and/or parameter data corresponding to a trainingoperation, etc.), instructions (e.g., software or firmware for thewelding training system, the sensing device 16, etc.), and any othersuitable data. As will be appreciated, data that corresponds to atraining operation may include a video recording of the trainingoperation, a simulated video, an orientation of the welding torch 14, aposition of the welding torch 14, a work angle, a travel angle, adistance between a contact tip of the welding torch 14 and a workpiece,a travel speed, a proximity, a voltage, a current, a traversed path, adiscontinuity analysis, welding device settings, and so forth.

The memory device(s) 22 may include a volatile memory, such as randomaccess memory (RAM), and/or a nonvolatile memory, such as read-onlymemory (ROM). The memory device(s) 22 may store a variety of informationand may be used for various purposes. For example, the memory device(s)22 may store processor-executable instructions (e.g., firmware orsoftware) for the processor(s) 20 to execute, such as instructions for awelding training simulation and/or for the sensing device 16. Inaddition, a variety of control regimes for various welding processes,along with associated settings and parameters may be stored in thestorage device(s) 24 and/or memory device(s) 22, along with codeconfigured to provide a specific output (e.g., initiate wire feed,enable gas flow, capture welding current data, detect short circuitparameters, determine amount of spatter, etc.) during operation.

As illustrated, the welding training system 10 includes a data reportingdevice 26; however, other embodiments may not include the data reportingdevice 26. The data reporting device 26 is configured to facilitateelectronic communication between the computer 18, the welding torch 14,a welding power supply 28, and/or a wire feeder 30. For example, thedata reporting device 26 may be configured to receive torch data fromthe welding torch 14, provide torch data to the computer 18, providedata to the welding torch 14, receive arc data from the wire feeder 30,provide arc data to the computer 18, and so forth. Furthermore, the datareporting device 26 may be configured to electronically communicate(e.g., either wired or wirelessly) with a device external to the weldingtraining system 10. The welding power supply 28 may be used to providewelding power to a live-arc welding operation, and the wire feeder 30may be used to provide welding wire to the live-arc welding operation.

The welding training system 10 includes a display 32 for displaying dataand/or screens associated with welding training (e.g., to display datacorresponding to a welding training software). For example, the display32 may provide a graphical user interface to a welding operator (e.g.,welding instructor, welding student). The graphical user interface mayprovide various screens to enable the welding instructor to organize aclass, provide assignments to the class, analyze assignments performedby the class, provide assignments to an individual, analyze assignmentsperformed by the individual, add, change, and/or delete parameters for awelding assignment, and so forth. Furthermore, the graphical userinterface may provide various screens to enable a welding operator(e.g., welding student) to perform a welding training assignment, viewresults from prior welding assignments, and so forth. In certainembodiments, the display 32 may be a touch screen display configured toreceive touch inputs, and to provide data corresponding to the touchinputs to the computer 18.

An external display 34 is coupled to the computer 18 to enable anindividual located remotely from the welding training system 10 to viewdata corresponding to the welding training system 10. Furthermore, anetwork device 36 is coupled to the computer 18 to enable the computer18 to communicate with other devices connected to the Internet oranother network 38 (e.g., for providing test results to another deviceand/or for receiving test results from another device). For example, thenetwork device 36 may enable the computer 18 to communicate with anexternal welding training system 40, a production welding system 42,and/or a remote computer 44. As may be appreciated, the welding trainingsystem 10 described herein may be used to train welding students in acost effective manner. Furthermore, the welding training system 10 isconfigured to integrate real welding with simulated welding in a mannerthat prepares welding students for high quality production welding.

Welding Torch

FIG. 2 is a block diagram of an embodiment of portions of the weldingtraining system 10 of FIG. 1. As illustrated, the data reporting device26 includes control circuitry 46 configured to provide data to and/or toreceive data from the wire feeder 30, the welding power supply 28, thewelding torch 14, and the computer 18. The control circuitry 46 is alsoconfigured to provide power to one or more devices, such as the weldingtorch 14. The data reporting device 26 also includes a communicationport 47 (e.g., universal serial bus (USB) port, a high speed serial busport, etc.) and light emitting diodes (LEDs) 48 that may be used toindicate a status of the data reporting device 26, for example. The datareporting device 26 includes a network interface 49 to facilitatecommunication between the data reporting device 26 and an externaldevice, such as the computer 18. The network interface 49 may be anysuitable device that facilitates wired and/or wireless communicationbetween the data reporting device 26 and the external device. The datareporting device 26 also includes a communication interface 50 tofacilitate communication between the data reporting device 26 and thewelding torch 14. In certain embodiments, the communication interface 50may include an RS-232 driver.

The welding torch 14 includes control circuitry 52 configured to controlthe operation of the welding torch 14. In the illustrated embodiment,the control circuitry 52 includes one or more processors 54, memorydevices 56, and storage devices 58. In other embodiments, the controlcircuitry 52 may not include the processors 54, the memory devices 56,and/or the storage devices 58. The processor(s) 54 may be used toexecute software, such as welding torch software. Moreover, theprocessor(s) 54 may be similar to the processor(s) 20 describedpreviously. Furthermore, the memory device(s) 56 may be similar to thememory device(s) 22, and the storage device(s) 58 may be similar to thestorage device(s) 24.

The welding torch 14 includes a user interface 60 to enable a weldingoperator (e.g., welding student, welding instructor, etc.) to interactwith the welding torch 14 and/or to provide inputs to the welding torch14. For example, the user interface 60 may include buttons, switches,touch screens, touchpads, and so forth. The inputs provided to thewelding torch 14 by the welding operator may be provided to the computer18. For example, the inputs provided to the welding torch 14 may be usedto control welding training software being executed by the computer 18.As such, the welding operator may use the user interface 60 on thewelding torch 14 to navigate the welding training software screens,setup procedures, data analysis, welding courses, make selections withinthe welding training software, configure the welding training software,and so forth. Thus, the welding operator can use the welding torch 14 tocontrol the welding training software (e.g., the welding operator doesnot have to put down the welding torch 14 to use a different inputdevice). The welding torch 14 also includes visual indicators 61, suchas a display 62 and LEDs 64. The visual indicators 61 may be configuredto indicate or display data and/or images corresponding to a weld,welding training, and/or welding training software. For example, thevisual indicators 61 may be configured to indicate a welding torchorientation, a welding torch travel speed, a welding torch position, acontact tip to workpiece distance, a proximity of the welding torch 14in relation to the workpiece, an aim of the welding torch 14 (e.g., atwhat point the welding torch 14 is directed), training information forthe welding operator, and so forth. Moreover, the visual indicators 61may be configured to provide visual indications before a weld, during aweld, and/or after a weld. In certain embodiments, the LEDs 64 mayilluminate to facilitate their detection by the sensing device 16. Insuch embodiments, the LEDs 64 may be positioned to enable the sensingdevice 16 to determine a position and/or an orientation of the weldingtorch 14 based on a spatial position of the LEDs 64.

In certain embodiments, the welding torch 14 includes power conversioncircuitry 66 configured to receive power from the data reporting device26 (e.g., or another device), and to convert the received power forpowering the welding torch 14. In certain embodiments, the welding torch14 may receive power that is already converted and/or does not utilizepower conversion. Moreover, in some embodiments, the welding torch 14may be powered by a battery or any suitable powering mechanism. Thewelding torch 14 also includes a communication interface 68 (e.g.,RS-232 driver) to facilitate communication between the welding torch 14and the data reporting device 26 (or another device). In the illustratedembodiment, the welding torch 14 may communicate with the computer 18 byproviding data to the data reporting device 26 using the communicationinterfaces 50 and 68, then the data reporting device 26 communicates thedata to the computer 18. Accordingly, inputs provided to the weldingtorch 14 may be provided to the computer 18. In certain embodiments, thewelding torch 14 may provide inputs to the computer 18 by communicatingdirectly with the computer 18.

The welding torch 14 includes a trigger 70 configured to mechanicallyactuate a trigger switch 72 between an open position (as illustrated)and a closed position. The trigger 70 provides a conductor 71 to carry asignal to the control circuitry 52 to indicate whether the triggerswitch 72 is in the open position or the closed position. The wirefeeder 30, the welding power supply 28, the computer 18, and/or the datareporting device 26 may determine whether there is continuity throughthe welding torch 14 across a first trigger conductor 74 and a secondtrigger conductor 76. The trigger switch 72 is electrically coupledbetween the first trigger conductor 74 and the second trigger conductor76. Continuity across the first trigger conductor 74 and the secondtrigger conductor 76 may be determined by applying a voltage across theconductors 74 and 76, applying a current across the conductors 74 and76, measuring a resistance across the conductors 74 and 76, and soforth. In certain embodiments, portions of the first trigger conductor74 and/or portions of the second trigger conductor 76 may be disposedwithin a connector of the welding torch 14. Furthermore, in certainembodiments, the arrangement of switches and/or conductors within thewelding torch 14 may be different than illustrated in FIG. 2.

The welding power supply 28 may determine whether to enable weldingpower to flow through the welding torch 14 based on whether there iscontinuity across the conductors 74 and 76. For example, the weldingpower supply 28 may enable welding power to flow through the weldingtorch 14 while there is continuity across the conductors 74 and 76, andthe welding power supply 28 may block welding power from flowing throughthe welding torch 14 while there is an open circuit across theconductors 74 and 76. Furthermore, the wire feeder 30 may providewelding wire to the welding torch 14 while there is continuity acrossthe conductors 74 and 76, and may block welding wire from being providedto the welding torch 14 while there is an open circuit across theconductors 74 and 76. Moreover, the computer 18 may use the continuityacross the conductors 74 and 76 and/or the position of the trigger 70 ortrigger switch 72 to start and/or stop a welding training operation, awelding training simulation, data recording, and so forth.

With the trigger switch 72 in the open position, there is an opencircuit across the conductors 74 and 76, thus, the open position of thetrigger switch 72 blocks electron flow between the conductors 74 and 76.Accordingly, the welding power supply 28 may block welding power fromflowing through the welding torch 14 and the wire feeder 30 may blockwelding wire from being provided to the welding torch 14. Pressing thetrigger 70 directs the trigger switch 72 to the closed position wherethe trigger switch 72 remains as long as the trigger 70 is pressed. Withthe trigger switch 72 in the closed position, there is continuitybetween the first trigger conductor 74 and a conductor 77 electricallyconnected to the trigger switch 72 and a training switch 78.

The training switch 78 is electrically coupled between the first triggerconductor 74 and the second trigger conductor 76. Moreover, the trainingswitch 78 is electrically controlled by the control circuitry 52 to anopen position or to a closed position. In certain embodiments, thetraining switch 78 may be any suitable electrically controlled switch,such as a transistor, relay, etc. The control circuitry 52 mayselectively control the training switch 78 to the open position or tothe closed position. For example, while welding training software of thewelding training system 10 is operating in a live-arc mode, the controlcircuitry 52 may be configured to control the training switch 78 to theclosed position to enable a live welding arc while the trigger 70 ispressed. In contrast, while welding training software of the weldingtraining system 10 is operating in any mode other than the live-arc mode(e.g., simulation, virtual reality, augmented reality, etc.), thecontrol circuitry 52 may be configured to control the training switch 78to the open position to block a live welding arc (by blocking electronflow between the conductors 74 and 76).

In certain embodiments, the training switch 78 may default to the openposition, thereby establishing an open circuit across the conductors 74and 76. As may be appreciated, while the training switch 78 is in theopen position, there will be an open circuit across the conductors 74and 76 regardless of the position of the trigger switch 72 (e.g.,electron flow between the conductors 74 and 76 is blocked by the openposition of the training switch 78). However, while the training switch78 is controlled to the closed position, and the trigger switch 72 is inthe closed position, conductivity is established between the conductors74 and 76 (e.g., electron flow between the conductors 74 and 76 isenabled). Accordingly, the welding power supply 28 may enable weldingpower to flow through the welding torch 14 only while the trainingswitch 78 is in the closed position and while the trigger switch 72 isin the closed position. For example, welding power may flow from thewelding power supply 28, through a weld cable 80, the welding torch 14,a workpiece 82, and return to the welding power supply 28 via a workcable 84 (e.g., electrode-negative, or straight polarity). Conversely,welding power may flow from the welding power supply 28, through thework cable 84, the workpiece 82, the welding torch 14, and return to thewelding power supply 28 via the weld cable 80 (e.g., electrode-positive,or reverse polarity).

As may be appreciated, the training switch 78 may be physically locatedin any suitable portion of the welding training system 10, such as thedata reporting device 26, the computer 18, and so forth. Furthermore, incertain embodiments, the functionality of the training switch 78 may bereplaced by any suitable hardware and/or software in the weldingtraining system 10.

FIG. 2A is a schematic diagram of an embodiment of circuitry of thewelding torch 14 of FIG. 1. In the illustrated embodiment, the triggerswitch 72 selectively connects a power supplying conductor (e.g.,voltage source, etc.) to the conductor 71. Accordingly, while thetrigger switch 72 is open, no voltage is applied to the conductor 71,and while the trigger switch 72 is closed, voltage from the powersupplying conductor is supplied to the conductor 71. A trigger enablesignal (e.g., TRIGGER_EN) may be provided by the control circuitry 52 toselectively control the training switch 78, and thereby control a feederenable switch 85. For example, when the trigger enable signal controlsthe training switch 78 to an open position, no voltage is applied to thefeeder enable switch 85 (e.g., via the FEEDER_EN connection), therebymaintaining the feeder enable switch 85 in the open position.Conversely, when the trigger enable signal controls the training switch78 to a closed position, voltage is applied to the feeder enable switch85, thereby controlling the feeder enable switch 85 to the closedposition. With the feeder enable switch 85 in the closed position,conductivity between the conductors 74 and 76 is established. While oneexample of welding torch 14 circuitry is provided, any suitablecircuitry may be used may be used within the welding torch 14.

FIG. 3 is a perspective view of an embodiment of the welding torch 14 ofFIGS. 1 and 2. As illustrated, the user interface 60 includes multiplebuttons 86 which may be used to provide inputs to the welding torch 14.For example, the buttons 86 may enable a welding operator to navigatethrough welding training software. Furthermore, the welding torch 14includes the display 62 which may show the welding operator datacorresponding to the welding training software, data corresponding to awelding operation, and so forth. As illustrated, the LEDs 64 may bepositioned at various locations on the welding torch 14. Accordingly,the LEDs 64 may be illuminated to facilitate detection by the sensingdevice 16.

Calibration Techniques

FIG. 4 is a perspective view of an embodiment of the training stand 12of FIG. 1. The training stand 12 includes a welding surface 88 on whichlive welds (e.g., real welds, actual welds) and/or simulated welds maybe performed. Legs 90 provide support to the welding surface 88. Thewelding surface 88 includes slots 91 that may aid a welding operator inpositioning and orienting the workpiece 84. In certain embodiments, theposition and orientation of the workpiece 84 may be provided to weldingtraining software of the welding training system 10 to calibrate thewelding training system 10. For example, a welding operator may providean indication to the welding training software identifying which slot 91of the welding surface 88 the workpiece 84 is aligned with. Furthermore,a predefined welding training assignment may direct the welding operatorto align the workpiece 84 with a particular slot 91. In certainembodiments, the workpiece 84 may include an extension 92 configured toextend into one or more of the slots 91 for alignment of the workpiece84 with the one or more slots 91. As may be appreciated, each of theslots 91 may be positioned at a location corresponding to a respectivelocation defined in the welding training software.

The welding surface 88 includes a first aperture 93 and a secondaperture 94. The first and second apertures 93 and 94 may be usedtogether to determine a position and/or an orientation of the weldingsurface 88. As may be appreciated, at least two apertures are used todetermine the position and/or the orientation of the welding surface 88.In certain embodiments, more than two apertures may be used to determinethe position and/or the orientation of the welding surface 88. The firstand second apertures 93 and 94 may be positioned at any suitablelocation on the welding surface 88, and may be any suitable size. Incertain embodiments, the position and/or orientation of the weldingsurface 88 relative to the sensing device 16 may be calibrated using thefirst and second apertures 93 and 94. For example, as described ingreater detail below, a calibration device configured to be sensed bythe sensing device 16 may be inserted into the first aperture 93, ortouched to the first aperture 93. While the calibration device isinserted into, or touching, the first aperture 93, a user input providedto the welding training software (or other calibration software) mayindicate that the calibration device is inserted into the first aperture93. As a result, the welding training software may establish acorrelation between a first data set (e.g., calibration data) receivedfrom the sensing device 16 (e.g., position and/or orientation data) at afirst time and the location of first aperture 93. The calibration devicemay next be inserted into the second aperture 94, or touched to thesecond aperture 94. While the calibration device is inserted into, ortouching, the second aperture 94, a user input provided to the weldingtraining software may indicate that the calibration device is insertedinto the second aperture 94. As a result, the welding training softwaremay establish a correlation between a second data set (e.g., calibrationdata) received from the sensing device 16 at a second time and thelocation of second aperture 94. Thus, the welding training software maybe able to calibrate the position and/or orientation of the weldingsurface 88 relative to the sensing device 16 using the first data setreceived at the first time and the second data set received at thesecond time.

The welding surface 88 also includes a first marker 95 and a secondmarker 96. The first and second markers 95 and 96 may be used togetherto determine a position and/or an orientation of the welding surface 88.As may be appreciated, at least two markers are used to determine theposition and/or the orientation of the welding surface 88. In certainembodiments, more than two markers may be used to determine the positionand/or the orientation of the welding surface 88. The first and secondmarkers 95 and 96 may be formed from any suitable material. Moreover, incertain embodiments, the first and second markers 95 and 96 may be builtinto the welding surface 88, while in other embodiments, the first andsecond markers 95 and 96 may be attached to the welding surface 88. Forexample, the first and second markers 95 and 96 may be attached to thewelding surface 88 using an adhesive and/or the first and second markers95 and 96 may be stickers. The first and second markers 95 and 96 mayhave any suitable shape, size, and/or color. Furthermore, in certainembodiments, the first and second markers 95 and 96 may be a reflectorformed from a reflective material. The first and second markers 95 and96 may be used by the welding training system 10 to calibrate theposition and/or orientation of the welding surface 88 relative to thesensing device 16 without a separate calibration device. Accordingly,the first and second markers 95 and 96 are configured to be detected bythe sensing device 16. In certain embodiments, the first and secondmarkers 95 and 96 may be positioned at predetermined locations on thewelding surface 88. Furthermore, the welding training software may beprogrammed to use the predetermined locations to determine the positionand/or the orientation of the welding surface 88. In other embodiments,the location of the first and second markers 95 and 96 may be providedto the welding training software during calibration. With the first andsecond markers 95 and 96 on the welding surface 88, the sensing device16 may sense the position and/or orientation of the first and secondmarkers 95 and 96 relative to the sensing device 16. Using this senseddata in conjunction with the location of the first and second markers 95and 96 on the welding surface 88, the welding training software may beable to calibrate the position and/or orientation of the welding surface88 relative to the sensing device 16.

In the illustrated embodiment, the workpiece 84 includes a first marker98 and a second marker 99. The first and second markers 98 and 99 may beused together to determine a position and/or an orientation of theworkpiece 84. As may be appreciated, at least two markers are used todetermine the position and/or the orientation of the workpiece 84. Incertain embodiments, more than two markers may be used to determine theposition and/or the orientation of the workpiece 84. The first andsecond markers 98 and 99 may be formed from any suitable material.Moreover, in certain embodiments, the first and second markers 98 and 99may be built into the workpiece 84, while in other embodiments, thefirst and second markers 98 and 99 may be attached to the workpiece 84.For example, the first and second markers 98 and 99 may be attached tothe workpiece 84 using an adhesive and/or the first and second markers98 and 99 may be stickers. The first and second markers 98 and 99 mayhave any suitable shape, size, and/or color. Furthermore, in certainembodiments, the first and second markers 98 and 99 may be a reflectorformed from a reflective material. The first and second markers 98 and99 may be used by the welding training system 10 to calibrate theposition and/or orientation of the workpiece 84 relative to the sensingdevice 16 without a separate calibration device. Accordingly, the firstand second markers 98 and 99 are configured to be detected by thesensing device 16. In certain embodiments, the first and second markers98 and 99 may be positioned at predetermined locations on the workpiece84. Furthermore, the welding training software may be programmed to usethe predetermined locations to determine the position and/or theorientation of the workpiece 84. In other embodiments, the location ofthe first and second markers 98 and 99 may be provided to the weldingtraining software during calibration. With the first and second markers98 and 99 on the workpiece 84, the sensing device 16 may sense theposition and/or orientation of the first and second markers 98 and 99relative to the sensing device 16. Using this sensed data in conjunctionwith the location of the first and second markers 98 and 99 on theworkpiece 84, the welding training software may be able to calibrate theposition and/or orientation of the workpiece 84 relative to the sensingdevice 16. While the markers 95, 96, 98, and 99 have been describedherein as being detected by the sensing device 16, in certainembodiments, the markers 95, 96, 98, and 99 may indicate locations wherea calibration device is to be touched for calibration using thecalibration device, as described previously.

The training stand 12 includes a first arm 100 extending vertically fromthe welding surface 88 and configured to provide support for the sensingdevice 16 and the display 32. A knob 101 is attached to the first arm100 and may be used to adjust an orientation of the sensing device 16relative to the first arm 100. For example, as the knob 101 is adjusted,mechanical components extending through the first arm 100 may adjust anangle of the sensing device 16. The display 32 includes a cover 102 toprotect the display 32 from welding emissions that may occur during alive welding operation. The cover 102 may be made from any suitablematerial, such as a transparent material, a polymer, and so forth. Byusing a transparent material, a welding operator may view the display 32while the cover 102 is positioned in front of the display 32, such asbefore, during, and/or after a welding operation. A camera 104 may becoupled to the first arm 100 for recording welding operations. Incertain embodiments, the camera 104 may be a high dynamic range (HDR)camera. Furthermore, an emitter 105 may be coupled to the first arm 100.The emitter 105 may be used to calibrate the position and/or orientationof the welding surface 88 relative to the sensing device 16. Forexample, the emitter 105 may be configured to emit a visible patternonto the welding surface 88. The visible pattern may be shown onto thewelding surface 88. Furthermore, the visible pattern may be detected bythe sensing device 16 to calibrate the position and/or the orientationof the welding surface 88 relative to the sensing device 16. Forexample, based on particular features of the visible pattern alignmentsand/or orientations may be determined by the sensing device 16 and/orthe welding training software. Moreover, the visible pattern emitted bythe emitter 105 may be used to facilitate positioning of the workpiece84 on the welding surface 88.

The training stand 12 also includes a second arm 106 extendingvertically from the welding surface 88 and configured to provide supportfor an overhead welding plate 108. The second arm 106 may be adjustableto facilitate overhead welding at different heights. Moreover, thesecond arm 106 may be manufactured in a number of different ways tofacilitate overhead welding at different heights. The overhead weldingplate 108 is coupled to the second arm 106 using a mounting assembly110. The mounting assembly 110 facilitates rotation of the overheadwelding plate 108 as illustrated by arrow 111. For example, the overheadwelding plate 108 may be rotated from extending generally in thehorizontal plane (e.g., for overhead welding), as illustrated, to extendgenerally in the vertical plane (e.g., for vertical welding). Theoverhead welding plate 108 includes a welding surface 112. The weldingsurface 112 includes slots 114 that may aid a welding operator inpositioning the workpiece 84 on the welding surface 112, similar to theslots 91 on the welding surface 88. In certain embodiments, the positionof the workpiece 84 may be provided to welding training software of thewelding training system 10 to calibrate the welding training system 10.For example, a welding operator may provide an indication to the weldingtraining software identifying which slot 114 of the welding surface 112the workpiece 84 is aligned with. Furthermore, a predefined weldingtraining assignment may direct the welding operator to align theworkpiece 84 with a particular slot 114. In certain embodiments, theworkpiece 84 may include an extension configured to extend into one ormore of the slots 114 for alignment of the workpiece 84 with the one ormore slots 114. As may be appreciated, each of the slots 114 may bepositioned at a location corresponding to a respective location definedin the welding training software.

The welding surface 112 also includes a first marker 116 and a secondmarker 118. The first and second markers 116 and 118 may be usedtogether to determine a position and/or an orientation of the weldingsurface 112. As may be appreciated, at least two markers are used todetermine the position and/or the orientation of the welding surface112. In certain embodiments, more than two markers may be used todetermine the position and/or the orientation of the welding surface112. The first and second markers 116 and 118 may be formed from anysuitable material. Moreover, in certain embodiments, the first andsecond markers 116 and 118 may be built into the welding surface 112 (oranother part of the overhead welding plate 108), while in otherembodiments, the first and second markers 116 and 118 may be attached tothe welding surface 112 (or another part of the overhead welding plate108). For example, the first and second markers 116 and 118 may beattached to the welding surface 112 using an adhesive and/or the firstand second markers 116 and 118 may be stickers. The first and secondmarkers 116 and 118 may have any suitable shape, size, and/or color.Furthermore, in certain embodiments, the first and second markers 116and 118 may be a reflector formed from a reflective material. The firstand second markers 116 and 118 may be used by the welding trainingsystem 10 to calibrate the position and/or orientation of the weldingsurface 112 relative to the sensing device 16 without a separatecalibration device. Accordingly, the first and second markers 116 and118 are configured to be detected by the sensing device 16. In certainembodiments, the first and second markers 116 and 118 may be positionedat predetermined locations on the welding surface 112. Furthermore, thewelding training software may be programmed to use the predeterminedlocations to determine the position and/or the orientation of thewelding surface 112. In other embodiments, the location of the first andsecond markers 116 and 118 may be provided to the welding trainingsoftware during calibration. With the first and second markers 116 and118 on the welding surface 112, the sensing device 16 may sense theposition and/or orientation of the first and second markers 116 and 118relative to the sensing device 16. Using this sensed data in conjunctionwith the location of the first and second markers 116 and 118 on thewelding surface 112, the welding training software may be able tocalibrate the position and/or orientation of the welding surface 112relative to the sensing device 16. Furthermore, the sensing device 16may sense and/or track the first and second markers 116 and 118 during aweld to account for any movement of the overhead welding plate 108 thatmay occur during the weld. While the markers 116 and 118 have beendescribed herein as being detected by the sensing device 16, in certainembodiments, the markers 116 and 118 may indicate locations where acalibration device is to be touched or inserted for calibration usingthe calibration device, as described previously.

FIG. 5 is a perspective view of an embodiment of a calibration device120. The calibration device 120 is shaped like a torch and may be usedfor calibrating the position and/or orientation of the welding surfaces88 and 112 relative to the sensing device 16, as described in greaterdetail above. The calibration device 120 includes a handle 122 and anozzle 124. The nozzle 124 includes a pointed end 126 that may be usedto touch a location for calibration and/or to be inserted into anaperture for calibration. The calibration device 120 also includes auser interface 128 that enables the welding operator to provide inputcorresponding to a time that the calibration device 120 is touching alocation for calibration and/or is being inserted into an aperture forcalibration. Moreover, in certain embodiments, the calibration device120 includes markers 130 configured to be sensed by the sensing device16. As illustrate, the markers 130 extend from the calibration device120. However, in other embodiments, the markers 130 may not extend fromthe calibration device 120. The markers 130 may be any suitable markerconfigured to be detected by the sensing device 16. Moreover, themarkers 130 may be any suitable size, shape, and/or color.

During calibration, the sensing device 16 may sense a position of thecalibration device 120 and/or an orientation of the calibration device120. The position and/or orientation of the calibration device 120 maybe used by the welding training software to determine a position and/ororientation of one or more of the welding surfaces 88 and 112 relativeto the sensing device 16, a position and/or orientation of the workpiece84 relative to the sensing device 16, a position and/or orientation of afixture relative to the sensing device 16, and so forth. Thus, thecalibration device 120 may facilitate calibration of the weldingtraining system 10.

FIG. 6 is a perspective view of an embodiment of a fixture assembly 132.The fixture assembly 132 may be positioned on the welding surface 88and/or the welding surface 112, and may secure the workpiece 84 thereon.In certain embodiments, the fixture assembly 132 may be configured toalign with one or more of the slots 92 and 114. In other embodiments,the fixture assembly 132 may be placed at any location on the weldingsurface 88 and/or the welding surface 122. The fixture assembly 132 alsoincludes a first marker 134 and a second marker 136. The first andsecond markers 134 and 136 may be used together to determine a positionand/or an orientation of the fixture assembly 132. As may beappreciated, at least two markers are used to determine the positionand/or the orientation of the fixture assembly 132. The first and secondmarkers 134 and 136 may be formed from any suitable material. Moreover,in certain embodiments, the first and second markers 134 and 136 may bebuilt into the fixture assembly 132, while in other embodiments, thefirst and second markers 134 and 136 may be attached to the fixtureassembly 132. For example, the first and second markers 134 and 136 maybe attached to the fixture assembly 132 using an adhesive and/or thefirst and second markers 134 and 136 may be stickers. The first andsecond markers 134 and 136 may have any suitable shape, size, and/orcolor. Furthermore, in certain embodiments, the first and second markers134 and 136 may be a reflector formed from a reflective material. Thefirst and second markers 134 and 136 may be used by the welding trainingsystem 10 to calibrate the position and/or orientation of the fixtureassembly 132 relative to the sensing device 16 without a separatecalibration device. Accordingly, the first and second markers 134 and136 are configured to be detected by the sensing device 16. In certainembodiments, the first and second markers 134 and 136 may be positionedat predetermined locations on the fixture assembly 132. Furthermore, thewelding training software may be programmed to use the predeterminedlocations to determine the position and/or the orientation of thefixture assembly 132. In other embodiments, the location of the firstand second markers 134 and 136 may be provided to the welding trainingsoftware during calibration. With the first and second markers 134 and136 on the fixture assembly 132, the sensing device 16 may sense theposition and/or orientation of the first and second markers 134 and 136relative to the sensing device 16. Using this sensed data in conjunctionwith the location of the first and second markers 134 and 136 on thefixture assembly 132, the welding training software may be able tocalibrate the position and/or orientation of the fixture assembly 132relative to the sensing device 16. While the first and second markers134 and 136 have been described herein as being detected by the sensingdevice 16, in certain embodiments, the first and second markers 134 and136 may indicate locations where a calibration device is to be touchedor inserted for calibration using the calibration device 120, asdescribed previously.

In the illustrated embodiment, the fixture assembly 132 is configured tosecure a lower portion 138 of the workpiece 84 to an upper portion 140of the workpiece 84 for performing a lap weld. In other embodiments, thefixture assembly 132 may be configured to secure portions of theworkpiece 84 for performing a butt weld, a fillet weld, and so forth, toaid a welding operator in performing a weld. The fixture assembly 132includes vertical arms 142 extending from a base 143. A cross bar 144extends between the vertical arms 142, and is secured to the verticalarms 142. Adjustment mechanisms 146 (e.g., knobs) may be adjusted todirect locking devices 148 toward the workpiece 84 for securing theworkpiece 84 between the locking devices 148 and the base 143 of thefixture assembly 132. Conversely, the adjustment mechanisms 146 may beadjusted to direct the locking devices 148 away from the workpiece 84for removing the workpiece 84 from being between the locking devices 148and the base 143. Accordingly, the workpiece 84 may be selectivelysecured to the fixture assembly 132.

Welding Training System Devices

FIG. 7 is a perspective view of a welding wire stickout calibration tool150. The tool 150 is configured to calibrate a length of welding wireextending out of a torch nozzle to a selectable length. Accordingly, thetool 150 includes a first handle 152 and a second handle 154. The tool150 also includes a torch nozzle holder 156 attached to a centralportion 157 of the tool 150 and extending outward from the centralportion 157 a selected distance. In the illustrated embodiment, thetorch nozzle holder 156 has a generally cylindrical body 158 (e.g., cupshape); however, in other embodiments, the body 158 of the torch nozzleholder 156 may have any suitable shape. Moreover, the torch nozzleholder 156 is configured to receive the torch nozzle through a nozzleinlet 160 such that the torch nozzle extends into the body 158.Furthermore, the torch nozzle holder 156 includes an opening 162configured to enable welding wire to extend out the end of the torchnozzle holder 156, and to block the torch nozzle from extending throughthe opening 162. As the torch nozzle extends into the torch nozzleholder 156, the welding wire extends out of the opening 162 of the torchnozzle holder 156 toward a blade assembly 164 of the tool 150. The bladeassembly 164 includes one or more sides 165 and 166 configured tocontact the welding wire. In certain embodiments, both of sides 165 and166 include blades to cut opposing sides of the welding wire, while inother embodiments, only one of the sides 165 and 166 includes a blade tocut one side of the welding wire and the other side includes a surfaceto which the blade is directed toward. For calibrating the length of thewelding wire, the welding wire may extend through the opening 162 andinto the blade assembly 164. The welding wire may be cut to a selectablelength by pressing the first handle 152 and the second handle 154 towardone another, thereby calibrating the length of wire extending from thetorch nozzle. The calibration length may be selected using an adjustmentmechanism 167 to adjust a distance 168 between the blade assembly 164and the opening 162 of the torch nozzle holder 156. Thus, using the tool150, the length of wire extending from the torch nozzle may becalibrated.

FIG. 8 is a top view of the welding wire stickout calibration tool 150of FIG. 7. As illustrated, the welding torch 14 may be used with thetool 150. Specifically, a nozzle 170 of the welding torch 14 may beinserted into the torch nozzle holder 156 in a direction 172. Weldingwire 174 extending from the welding torch 14 is directed through thenozzle inlet 160, the opening 162, and the blade assembly 164.Accordingly, the first and second handles 152 and 154 may be pressedtogether to cut the welding wire 174 to the distance 168 (e.g., thecalibration length) set by the adjustment mechanism 167.

FIG. 9 is an embodiment of a method 176 for calibrating wire stickoutfrom the welding torch 14. The tool 150 may be used to calibrate thelength of welding wire 174 extending from the nozzle 170 using a varietyof methods. In the method 176, the adjustment mechanism 167 of thewelding wire stickout calibration tool 150 may be adjusted for aselected welding wire 174 length (block 178). For example, the distance168 of the torch nozzle holder 156 from the tool 150 may be set to arange of between approximately 0.5 to 2.0 cm, 1.0 to 3.0 cm, and soforth. The welding torch 14 may be inserted into the torch nozzle holder156 of the tool 150, such that the nozzle 170 of the welding torch 14abuts the torch nozzle holder 156, and that the welding wire 174 extendsthrough the opening 162 of the torch nozzle holder 156 (block 180). Incertain embodiments, the welding wire 174 may be long enough to extendthrough the blade assembly 164. However, if the welding wire 174 doesnot extend through the blade assembly 164, a welding operator mayactuate the trigger 70 of the welding torch 14 to feed welding wire 174such that the welding wire 174 extends through the blade assembly 164(block 182). Accordingly, the welding operator may compress handles 152and 154 of the tool 150 to cut the welding wire 174 extending throughthe blade assembly 164 and thereby calibrate the length of the weldingwire 174 (block 184).

FIG. 10 is a perspective view of an embodiment of a welding consumable186 having physical marks. The welding consumable 186 may be anysuitable welding consumable, such as a welding stick, welding rod, or awelding electrode. The welding consumable 186 includes physical marks188, 190, 192, 194, 196, 198, 200, 202, and 204. The physical marks 188,190, 192, 194, 196, 198, 200, 202, and 204 may be any suitable physicalmark. For example, the physical marks 188, 190, 192, 194, 196, 198, 200,202, and 204 may include a bar code, an image, a shape, a color, text, aset of data, and so forth. In certain embodiments, the physical marks188, 190, 192, 194, 196, 198, 200, 202, and 204 may be laser etched.Furthermore, in certain embodiments, the physical marks 188, 190, 192,194, 196, 198, 200, 202, and 204 may be visible with the natural eye(e.g., within the visible spectrum), while in other embodiments thephysical marks 188, 190, 192, 194, 196, 198, 200, 202, and 204 may notbe visible with the natural eye (e.g., not within the visible spectrum).

Each of the physical marks 188, 190, 192, 194, 196, 198, 200, 202, and204 indicates a location on the welding consumable 186 relative toeither a first end 206, or a second end 208 of the welding consumable186. For example, the physical mark 188 may indicate a distance from thefirst end 206, a distance from the second end 208, or some otherlocation relative to the welding consumable 186. In certain embodiments,the physical marks 188, 190, 192, 194, 196, 198, 200, 202, and 204 mayindicate a number that corresponds to the first end 206 and/or thesecond end 208. For example, the physical mark 188 may indicate a number“1” indicating that it is the first physical mark from the first end 206and/or the physical mark 188 may indicate a number “9” indicating thatit is the ninth physical mark from the second end 208. A processingdevice may use a lookup table to determine a distance from the first end206 or the second end 208 based on the number indicated by the physicalmark.

A camera-based detection system, which may include the sensing device16, or another type of system is configured to detect the physical marks188, 190, 192, 194, 196, 198, 200, 202, and 204 during live arc weldingor a welding simulation. Moreover, the camera-based detection system isconfigured to determine a remaining length of the welding consumable186, a consumed length of the welding consumable 186, a rate of use ofthe welding consumable 186, a dipping rate of the welding consumable186, and so forth, based on the detected physical marks. Accordingly,data corresponding to use of the welding consumable 186 may be trackedby the welding training system 10 for training and/or analysis.

FIG. 11 is a perspective view of an embodiment of welding wire 210having physical marks 212, 214, 216, and 218. The physical marks 212,214, 216, and 218 may be any suitable physical mark. For example, thephysical marks 212, 214, 216, and 218 may include a bar code, an image,a shape, text, a set of data, and so forth. In certain embodiments, thephysical marks 212, 214, 216, and 218 may be laser etched. Furthermore,in certain embodiments, the physical marks 212, 214, 216, and 218 may bevisible with the natural eye (e.g., within the visible spectrum), whilein other embodiments the physical marks 212, 214, 216, and 218 may notbe visible with the natural eye (e.g., not within the visible spectrum).

Each of the physical marks 212, 214, 216, and 218 indicates a locationon the welding wire 210 relative to either a first end 220, or a secondend 222 of the welding wire 210. For example, the physical mark 212 mayindicate a distance from the first end 220, a distance from the secondend 222, or some other location relative to the welding wire 210. Incertain embodiments, the physical marks 212, 214, 216, and 218 mayindicate a number that corresponds to the first end 220 and/or thesecond end 222. For example, the physical mark 212 may indicate a number“1” indicating that it is the first physical mark from the first end 220and/or the physical mark 212 may indicate a number “4” indicating thatit is the fourth physical mark from the second end 222. A processingdevice may use a lookup table to determine a distance from the first end220 or the second end 222 based on the number indicated by the physicalmark.

A camera-based detection system, which may include the sensing device16, or another type of system is configured to detect the physical marks212, 214, 216, and 218 during live arc welding or a welding simulation.Moreover, the camera-based detection system is configured to determine aremaining length of the welding wire 210, a consumed length of thewelding wire 210, a rate of use of the welding wire 210, a dipping rateof the welding wire 210, and so forth, based on the detected physicalmarks. Accordingly, data corresponding to use of the welding wire 210may be tracked by the welding training system 10 for training and/oranalysis.

FIG. 12 is a perspective view of an embodiment of a vertical armassembly 223 of the training stand 12 of FIG. 4. As illustrated, thesensing device 16 is attached to the first arm 100. Furthermore, thesensing device 16 includes cameras 224, and an infrared emitter 226.However, in other embodiments, the sensing device 16 may include anysuitable number of cameras, emitters, and/or other sensing devices. Apivot assembly 228 is coupled to the first arm 100 and to the sensingdevice 16, and enables an angle of the sensing device 16 to be adjustedwhile the sensing device 16 rotates as illustrated by arrow 229. As maybe appreciated, adjusting the angle of the sensing device 16 relative tothe first arm 100 changes the field of view of the sensing device 16(e.g., to change the portion of the welding surface 88 and/or thewelding surface 112 sensed by the sensing device 16).

A cord 230 extends between the knob 101 and the sensing device 16. Thecord 230 is routed through a pulley 232 to facilitate rotation of thesensing device 16. Thus, a welding operator may rotate the knob 101 tomanually adjust the angle of the sensing device 16. As may beappreciated, the combination of the cord 230 and the pulley 232 is oneexample of a system for rotating the sensing device 16. It should benoted that any suitable system may be used to facilitate rotation of thesensing device 16. While one embodiment of a knob 101 is illustrated, itmay be appreciated that any suitable knob may be used to adjust theangle of the sensing device 16. Furthermore, the angle of the sensingdevice 16 may be adjusted using a motor 234 coupled to the cord 230.Accordingly, a welding operator may operate the motor 234 to adjust theangle of the sensing device 16. Moreover, in certain embodiments,control circuitry may be coupled to the motor 234 and may control theangle of the sensing device 16 based on a desired field of view of thesensing device 16 and/or based on tracking of an object within the fieldof view of the sensing device 16.

FIG. 13 is a perspective view of an embodiment of an overhead weldingarm assembly 235. The overhead welding arm assembly 235 illustrates oneembodiment of a manufacturing design that enables the second arm 106 tohave an adjustable height. Accordingly, as may be appreciated, thesecond arm 106 may be manufactured to have an adjustable height in anumber of ways. As illustrated, the overhead welding assembly 235includes handles 236 used to vertically raise and/or lower the secondarm 106 as illustrated by arrows 238. The overhead welding arm assembly235 includes a locking device 240 to lock the second arm 106 at adesired height. For example, the locking device 240 may include a buttonthat is pressed to disengage a latch configured to extend into openings242, thus unlocking the second arm 106 from being secured to side rails243. With the second arm 106 unlocked from the side rails 243, thehandles 236 may be vertically adjusted to a desired height, therebyadjusting the plate 112 to a desired height. As may be appreciated,releasing the button may result in the latch extending into the openings242 and locking the second arm 106 to the side rails 243. As may beappreciated, the locking device 240 may operate manually as describedand/or the locking device 240 may be controlled by a control system(e.g., automatically controlled). Furthermore, the second arm 106 may bevertically raised and/or lowered using the control system. For example,in certain embodiments, the welding training software may control thesecond arm 106 to move to a desired position automatically. Thus, theplate 112 may be adjusted to a desired height for overhead welding.

Multi-Mode Welding Training Software

FIG. 14 is a block diagram of an embodiment of welding training software244 of the welding training system 10 having multiple training modes. Asillustrated, the welding training software 244 may include one or moreof a live-arc mode 246 configured to enable training using a live (e.g.,actual) welding arc, a simulation mode 248 configured to enable trainingusing a welding simulation, a virtual reality (VR) mode 250 configuredto enable training using a VR simulation, and/or an augmented realitymode 252 configured to enable training using augmented realitysimulation.

The welding training software 244 may receive signals from an audioinput 254. The audio input 254 may be configured to enable a weldingoperator to operate the welding training software 244 using audiblecommands (e.g., voice activation). Furthermore, the welding trainingsoftware 244 may be configured to provide an audio output 256 and/or avideo output 258. For example, the welding training software 244 mayprovide audible information to a welding operator using the audio output256. Such audible information may include instructions for configuring(e.g., setting up) the welding training system 10, real-time feedbackprovided to a welding operator during a welding operation, instructionsto a welding operator before performing a welding operation,instructions to a welding operator after performing a welding operation,warnings, and so forth.

FIG. 15 is a block diagram of an embodiment of the VR mode 250 of thewelding training software 244. The VR mode 250 is configured to providea welding operator with a VR simulation 260. The VR simulation 260 maybe displayed to a welding operator through a VR headset, VR glasses, aVR display, or any suitable VR device. The VR simulation 260 may beconfigured to include a variety of virtual objects, such as the objectsillustrated in FIG. 15, that enable interaction between a weldingoperator and a selected virtual object of the variety of virtual objectswithin the VR simulation 260. For example, virtual objects may include avirtual workpiece 262, a virtual welding stand 264, a virtual weldingtorch 266, virtual wire cutters 268, virtual software configuration 270,virtual training data results 272, and/or a virtual glove 274.

In certain embodiments, the welding operator may interact with thevirtual objects without touching a physical object. For example, thesensing device 16 may detect movement of the welding operator and mayresult in similar movements occurring in the VR simulation 260 based onthe welder operator's movements in the real world. In other embodiments,the welding operator may use a glove or the welding torch 14 to interactwith the virtual objects. For example, the glove or the welding torch 14may be detected by the sensing device 16, and/or the glove or thewelding torch 14 may correspond to a virtual object in the VR simulation260. Furthermore, the welding operator may be able to operate thewelding training software 244 within the VR simulation 260 using thevirtual software configuration 270 and/or the virtual training dataresults 272. For example, the welding operator may use their hand, theglove, or the welding torch 14 to select items within the weldingtraining software 244 that are displayed virtually within the VRsimulation 260. Moreover, the welding operator may perform other actionssuch as picking up wire cutters and cutting virtual welding wireextending from the virtual torch 266, all within the VR simulation 260.

FIG. 16 is an embodiment of a method 276 for integrating trainingresults data. The method 276 includes the welding training software 244of the computer 18 receiving a first set of welding training data from astorage device (e.g., storage device 24) (block 278). The first set ofwelding training data may include welding training data corresponding toa first welding training assignment. The method 276 also includes thewelding training software 244 receiving a second set of welding trainingdata from the storage device (block 280). In certain embodiments, thefirst set and/or second set of welding training data may be receivedfrom a network storage device. The network storage device may beconfigured to receive welding training data from and/or to providewelding training data to the welding training system 10 and/or theexternal welding training system 40. The welding training software 244may integrate the first and second sets of welding training data into achart to enable a visual comparison of the first set of welding trainingdata with the second set of welding training data (block 282). As may beappreciated, the chart may be a bar chart, a pie chart, a line chart, ahistogram, and so forth. In certain embodiments, integrating the firstset of welding training data with the second set of welding trainingdata includes filtering the first set of welding training data and thesecond set of welding training data to display a subset of the first setof welding training data and a subset of the second set of weldingtraining data. The welding training software 244 may provide the chartto a display device (e.g., the display 32) (block 284). In certainembodiments, providing the chart to the display device includesproviding selectable elements on the chart that when selected displaydata corresponding to a respective selected element of the selectableelements (e.g., selecting wire speed from the chart may change thescreen to display the wire speed history for a particular weldingtraining assignment).

The first set of welding training data and/or the second set of weldingtraining data may include a welding torch orientation, a welding torchtravel speed, a welding torch position, a contact tip to workpiecedistance, a proximity of the welding torch in relation to the workpiece,an aim of the welding torch, a welding score, a welding grade, and soforth. Moreover, the first set of welding training data and the secondset of welding training data may correspond to training performed by onewelding operator and/or by a class of welding operators. Furthermore,the first welding training assignment and the second welding trainingassignment may correspond to training performed by one welding operatorand/or by a class of welding operators. In certain embodiments, thefirst welding training assignment may correspond to training performedby a first welding operator, and the second welding training assignmentmay correspond to welding performed by a second welding operator.Moreover, the first training assignment and the second trainingassignment may correspond to the same welding training scenario.

FIG. 17 is an embodiment of a chart 285 illustrating multiple sets ofwelding training data for a welding operator. The chart 285 may beproduced by the welding training software 244 and may be provided to thedisplay 32 to be used by a welding instructor to review welding trainingoperators performed by a welding student, and/or may be provided to thedisplay 32 to be used by a welding student to review welding trainingoperations performed by that welding student. The chart 285 illustratesa bar graph comparison between different training assignments of a firstset of welding training assignments performed by a welding operator. Thefirst set of welding training assignments includes assignments 286, 288,290, 292, and 294. The chart 285 also illustrates a bar graph comparisonbetween different training assignments of a second set of weldingtraining assignments performed by the welding operator. The second setof welding training assignments includes assignments 296, 298, 300, 302,and 304. Accordingly, welding training assignments may be compared toone another for analysis, instruction, certification, and/or trainingpurposes. As illustrated, the welding training assignments may becompared to one another using one of any number of criteria, such as atotal score, a work angle, a travel angle, a travel speed, a contact towork distance, a proximity, a mode (e.g., live-arc mode, simulationmode, etc.), a completion status (e.g., complete, incomplete, partiallycomplete, etc.), a joint type (e.g., fillet, butt, T, lap, etc.), awelding position (e.g., flat, vertical, overhead, etc.), a type of metalused, a type of filler metal, and so forth.

FIG. 18 is an embodiment of a chart 305 illustrating welding trainingdata for a welder compared to welding training data for a class. Forexample, the chart 305 illustrates a score 306 of a welding operatorcompared to a score 308 (e.g., average, median, or some other score) ofa class for a first assignment. Furthermore, a score 310 of the weldingoperator is compared to a score 312 (e.g., average, median, or someother score) of the class for a second assignment. Moreover, a score 314of the welding operator is compared to a score 316 (e.g., average,median, or some other score) of the class for a third assignment. As maybe appreciated, scores from one or more welding operators may becompared to scores of the entire class. Such a comparison enables awelding instructor to assess the progress of individual welding studentsas compared to the class of welding students. Furthermore, scores fromone or more welding operators may be compared to scores of one or moreother welding operators. In certain embodiments, scores from one classmay be compared to scores of another class. Moreover, scores from thefirst assignment, the second assignment, and/or the third assignment maybe selected for comparison.

Data Storage and Analysis

FIG. 19 is a block diagram of an embodiment of a data storage system 318for storing certification status data. The certification status data maybe produced as a welding operator completes various assignments in thewelding training system 10. For example, a predetermined set ofassignments may certify a welding operator for a particular weldingdevice and/or welding process. The data storage system 318 includescontrol circuitry 320, one or more memory devices 322, and one or morestorage devices 324. The control circuitry 320 may include one or moreprocessors, which may be similar to the processor(s) 20. Furthermore,the memory device(s) 322 may be similar to the memory device(s) 22, andthe storage device(s) 324 may be similar to the storage device(s) 24.The memory device(s) 322 and/or the storage device(s) 324 may beconfigured to store certification status data 326 corresponding to awelding training certification of a welding operator.

The certification status data 326 may include welding training data ofthe welding operator (e.g., any data that is related to the assignmentsto certify the welding operator), any data related to an actualcertification (e.g., certified, not certified, qualified, not qualified,etc.), a quantity of one or more welds performed by the weldingoperator, a timestamp for one or more welds performed by the weldingoperator, welding parameter data for one or more welds performed by thewelding operator, a quality ranking of the welding operator, a qualitylevel of the welding operator, a history of training welds performed bythe welding operator, a history of production welds performed by thewelding operator, a first welding process (e.g., a metal inert gas (MIG)welding process, a tungsten inert gas (TIG) welding process, a stickwelding process, etc.) certification status (e.g., the welding operatoris certified for the first welding process, the welding operator is notcertified for the first welding process), a second welding processcertification status (e.g., the welding operator is certified for thesecond welding process, the welding operator is not certified for thesecond welding process), a first welding device (e.g., a wire feeder, apower supply, a model number, etc.) certification status (e.g., thewelding operator is certified for the first welding device, the weldingoperator is not certified for the first welding device), and/or a secondwelding device certification status (e.g., the welding operator iscertified for the second welding device, the welding operator is notcertified for the second welding device).

The control circuitry 320 may be configured to receive a request for thefirst welding process certification status, the second welding processcertification status, the first welding device certification status,and/or the second welding device certification status of the weldingoperator. Furthermore, the control circuitry 320 may be configured toprovide a response to the request. The response to the request mayinclude the first welding process certification status, the secondwelding process certification status, the first welding devicecertification status, and/or the second welding device certificationstatus of the welding operator. In certain embodiments, the weldingoperator may be authorized to use a first welding process, a secondwelding process, a first welding device, and/or a second welding devicebased at least partly on the response. Furthermore, in some embodiments,the first welding process, the second welding process, the first weldingdevice, and/or the second welding device of a welding system may beenabled or disabled based at least partly on the response. Moreover, incertain embodiments, the first welding process, the second weldingprocess, the first welding device, and/or the second welding device of awelding system may be enabled or disabled automatically. Thus, a weldingoperator's certification data may be used to enable and/or disable thatwelding operator's ability to use a particular welding system, weldingdevice, and/or welding process. For example, a welding operator may havea certification for a first welding process, but not for a secondwelding process. Accordingly, in certain embodiments, a welding operatormay verify their identity at a welding system (e.g., by logging in orsome other form of authentication). After the identity of the weldingoperator is verified, the welding system may check the weldingoperator's certification status. The welding system may enable thewelding operator to perform operations using the first welding processbased on the welding operator's certification status, but may block thewelding operator from performing the second welding process based on thewelding operator's certification status.

FIG. 20 is an embodiment of a screen 327 illustrating data correspondingto a training weld. The screen 327 may be produced by the weldingtraining software 244 and may be displayed on the display 32. The screen327 illustrates parameters that may be graphically displayed to awelding operator before, during, and/or after performing a weldingoperation. For example, the parameters may include a work angle 328, atravel angle 330, a contact tip to workpiece distance 332, a weldingtorch travel speed 334, a proximity of the welding torch in relation tothe workpiece 336, a welding voltage 337, a welding current 338, awelding torch orientation, a welding torch position, an aim of thewelding torch, and so forth.

As illustrated, graphically illustrated parameters may include anindication 339 of a current value of a parameter (e.g., while performinga welding assignment). Furthermore, a graph 340 may show a history ofthe value of the parameter, and a score 341 may show an overallpercentage that corresponds to how much time during the weldingassignment that the welding operator was within a range of acceptablevalues. In certain embodiments, a video replay 342 of a weldingassignment may be provided on the screen 327. The video replay 342 mayshow live video of a welding operator performing a real weld, live videoof the welding operator performing a simulated weld, live video of thewelding operator performing a virtual reality weld, live video of thewelding operator performing an augmented reality weld, live video of awelding arc, live video of a weld puddle, and/or simulated video of awelding operation.

In certain embodiments, the welding training system 10 may capture videodata during a welding assignment, and store the video data on thestorage device 24. Moreover, the welding training software 244 may beconfigured to retrieve the video data from the storage device 24, toretrieve welding parameter data from the storage device 24, tosynchronize the video data with the welding parameter data, and toprovide the synchronized video and welding parameter data to the display32.

The welding training software 244 may analyze welding parameter data todetermine a traversed path 344 that may be shown on the display 32. Insome embodiments, a time 346 during a weld may be selected by a weldingoperator. By selecting the time 346, the welding operator may view thevideo replay 342 and/or the traversed path 344 in conjunction with thewelding parameters as they were at the selected time 346 in order toestablish a correlation between the welding parameters, the video replay342, and/or the traversed path 344. The welding training software 244may be configured to recreate welding training data based at leastpartly on welding parameter data, to synchronize the video replay 342with the recreated welding training data, and to provide thesynchronized video replay 342 and recreated welding training data to thedisplay 32. In certain embodiments, the recreated welding training datamay be weld puddle data and/or a simulated weld.

In certain embodiments, the storage device 24 may be configured to storea first data set corresponding to multiple training welds performed by awelding operator, and to store a second data set corresponding tomultiple non-training welds performed by the welding operator.Furthermore, the control circuitry 320 may be configured to retrieve atleast part of the first data set from the storage device 24, to retrieveat least part of the second data set from the storage device 24, tosynchronize the at least part of the first data set with the at leastpart of the second data set, and to provide the synchronized at leastpart of the first data set and at least part of the second data set tothe display 32.

FIG. 21 is an embodiment of a screen 347 illustrating a discontinuityanalysis 348 of a training weld. The discontinuity analysis 348 includesa listing 350 that may itemize potential issues with a weldingoperation. The discontinuity analysis 348 provides feedback to thewelding operator regarding time periods within the welding operation inwhich the weld does not meet a predetermined quality threshold. Forexample, between times 352 and 354, there is a high discontinuity (e.g.,the welding quality is poor, the weld has a high probability of failure,the weld is defective). Furthermore, between times 356 and 358, there isa medium discontinuity (e.g., the welding quality is average, the weldhas a medium probability of failure, the weld is partially defective).Moreover, between times 360 and 362, there is a high discontinuity, andbetween times 364 and 366, there is a low discontinuity (e.g., thewelding quality is good, the weld has a low probability of failure, theweld is not defective). With this information a welding operator may beable to quickly analyze the quality of a welding operation.

FIG. 22 is a block diagram of an embodiment of a welding instructorscreen 368 of the welding training software 244. The welding trainingsoftware 244 is configured to provide training simulations for manydifferent welding configurations. For example, the weldingconfigurations may include a MIG welding process 370, a TIG weldingprocess 372, a stick welding process 374, the live-arc welding mode 346,the simulation welding mode 248, the virtual reality welding mode 250,and/or the augmented reality welding mode 252.

The welding instructor screen 368 may be configured to enable a weldinginstructor to restrict training of a welding operator 376 (e.g., to oneor more selected welding configurations), to restrict training of aclass of welding operators 378 (e.g., to one or more selected weldingconfigurations), and/or to restrict training of a portion of a class ofwelding operators 380 (e.g., to one or more selected weldingconfigurations). Moreover, the welding instructor screen 368 may beconfigured to enable the welding instructor to assign selected trainingassignments to the welding operator 382, to assign selected trainingassignments to a class of welding operators 384, and/or to assignselected training assignments to a portion of a class of weldingoperators 386. Furthermore, the welding instructor screen 368 may beconfigured to enable the welding instructor to automatically advance thewelding operator (or a class of welding operators) from a first trainingassignment to a second training assignment 388. For example, the weldingoperator may advance from a first training assignment to a secondtraining assignment based at least partly on a quality of performing thefirst training assignment.

FIG. 23 is an embodiment of a method 389 for weld training usingaugmented reality. A welding operator may select a training mode of thewelding training software 244 (block 390). The welding training software244 determines whether the augmented reality mode 252 has been selected(block 392). If the augmented reality mode 252 has been selected, thewelding training software 244 executes an augmented reality simulation.It should be noted that the welding operator may be wearing a weldinghelmet and/or some other headgear configured to position a displaydevice in front of the welding operator's view. Furthermore, the displaydevice may generally be transparent to enable the welding operator toview actual objects; however, a virtual welding environment may beportrayed on portions of the display device. As part of this augmentedreality simulation, the welding training software 244 receives aposition and/or an orientation of the welding torch 14, such as from thesensing device 16 (block 394). The welding training software 244integrates the virtual welding environment with the position and/or theorientation of the welding torch 14 (block 396). Moreover, the weldingtraining software 244 provides the integrated virtual weldingenvironment to the display device (block 398). For example, the weldingtraining software 244 may determine where a weld bead should bepositioned within the welding operator's field of view, and the weldingtraining software 244 may display the weld bead on the display devicesuch that the weld bead appears to be on a workpiece. After completionof the weld, the augmented reality simulation may enable the weldingoperator to erase a portion of the virtual welding environment (e.g.,the weld bead) (block 400), and the welding training software 244returns to block 390.

If the augmented realty mode 252 has not been selected, the weldingtraining software 244 determines whether the live-arc mode 246 has beenselected (block 402). If the live-arc mode 246 has been selected, thewelding training software 244 enters the live-arc mode 246 and thewelding operator may perform the live-arc weld (block 404). If thelive-arc mode 246 has not been selected and/or after executing block404, the welding training software 244 returns to block 390.Accordingly, the welding training software 244 is configured to enable awelding operator to practice a weld in the augmented reality mode 252,to erase at least a portion of the virtual welding environment from thepractice weld, and to perform a live weld in the live-arc mode 246. Incertain embodiments, the welding operator may practice the weld in theaugmented reality mode 252 consecutively a multiple number of times.

FIG. 24 is an embodiment of another method 406 for weld training usingaugmented reality. A welding operator may select a training mode of thewelding training software 244 (block 408). The welding training software244 determines whether the augmented reality mode 252 has been selected(block 410). If the augmented reality mode 252 has been selected, thewelding training software 244 executes an augmented reality simulation.It should be noted that the welding operator may be wearing a weldinghelmet and/or some other headgear configured to position a displaydevice in front of the welding operator's view. Furthermore, the displaydevice may completely block the welding operator's field of vision suchthat images observed by the welding operator have been captured by acamera and displayed on the display device. As part of this augmentedreality simulation, the welding training software 244 receives an imageof the welding torch 14, such as from the sensing device 16 (block 412).The welding training software 244 integrates the virtual weldingenvironment with the image of the welding torch 14 (block 414).Moreover, the welding training software 244 provides the integratedvirtual welding environment with the image of the welding torch 14 tothe display device (block 416). For example, the welding trainingsoftware 244 may determine where a weld bead should be positioned withinthe welding operator's field of view and the welding training software244 displays the weld bead on the display device with the image of thewelding torch 14 and other objects in the welding environment. Aftercompletion of the weld, the augmented reality simulation may enable thewelding operator to erase a portion of the virtual welding environment(e.g., the weld bead) (block 418), and the welding training software 244returns to block 408.

If the augmented realty mode 252 has not been selected, the weldingtraining software 244 determines whether the live-arc mode 246 has beenselected (block 420). If the live-arc mode 246 has been selected, thewelding training software 244 enters the live-arc mode 246 and thewelding operator may perform the live-arc weld (block 422). If thelive-arc mode 246 has not been selected and/or after executing block422, the welding training software 244 returns to block 408.Accordingly, the welding training software 244 is configured to enable awelding operator to practice a weld in the augmented reality mode 252,to erase at least a portion of the virtual welding environment from thepractice weld, and to perform a live weld in the live-arc mode 246. Incertain embodiments, the welding operator may practice the weld in theaugmented reality mode 252 consecutively a multiple number of times.

As may be appreciated, using the systems, devices, and techniquesdescribed herein, a welding training system 10 may be provided fortraining welding operators. The welding training system 10 may be costefficient and may enable welding students to receive high quality handson training.

While only certain features of the invention have been illustrated anddescribed herein, many modifications and changes will occur to thoseskilled in the art. It is, therefore, to be understood that the appendedclaims are intended to cover all such modifications and changes as fallwithin the true spirit of the invention.

The invention claimed is:
 1. A welding consumable comprising: a weldingrod configured for a stick welding process, the welding rod comprising:a first physical mark indicating a first location on the welding rodproximate to a first end of the welding rod; and a second physical markindicating a second location on the welding rod proximate to a secondend of the welding rod; wherein the first physical mark and the secondphysical mark are configured to be detected by a camera-based detectionsystem to determine a remaining length of the welding rod, a consumedlength of the welding rod, a rate of use of the welding rod, a dippingrate of the welding rod, or some combination thereof.
 2. The weldingconsumable of claim 1, wherein the first physical mark and the secondphysical mark are laser etched.
 3. The welding consumable of claim 1,wherein the first physical mark and the second physical mark are notwithin a visible spectrum.
 4. The welding consumable of claim 1, whereinthe first physical mark comprises a first bar code, and the secondphysical mark comprises a second bar code different from the first barcode.
 5. The welding consumable of claim 1, comprising a third physicalmark indicating a third location on the welding rod.
 6. The weldingconsumable of claim 1, wherein the first physical mark comprises a firstset of data corresponding to a first distance between the first physicalmark and an end of the welding rod, and the second physical markcomprises a second set of data corresponding to a second distancebetween the second physical mark and the end of the welding rod.
 7. Awelding training system comprising: a camera-based detection system; anda welding rod configured for a stick welding process, the welding rodcomprising: a first physical mark indicating a first location on thewelding rod offset by a first distance from a first end of the weldingrod; and a second physical mark indicating a second location on thewelding rod offset by a second distance from a second end of the weldingrod; wherein the first physical mark and the second physical mark areconfigured to be detected by the camera-based detection system todetermine a remaining length of the welding rod, a consumed length ofthe welding rod, a rate of use of the welding rod, a dipping rate of thewelding rod, or some combination thereof.
 8. A welding training systemcomprising: a welding surface, wherein the welding surface is configuredfor live welds or simulated welds to be performed on the weldingsurface; a sensor configured to sense a position of a welding torch, anorientation of the welding torch, or some combination thereof; a firstarm coupled to the welding surface, and extending vertically from thewelding surface; and a pivot assembly directly coupled to the first armand directly coupled to the sensor, wherein the pivot assembly isdisposed between the first arm and the sensor, and the pivot assemblyenables adjustment of an angle between the first arm and the sensor. 9.The welding training system of claim 8, wherein the angle between thefirst arm and the sensor is manually adjusted to change a portion of thewelding surface sensed by the sensor.
 10. The welding training system ofclaim 8, comprising a control system configured to adjust the anglebetween the first arm and the sensor to change a portion of the weldingsurface sensed by the sensor.
 11. The welding training system of claim8, comprising a second arm coupled to the welding surface, and arotatable bracket coupled to the second arm, wherein the second armextends vertically from the welding surface.
 12. The welding trainingsystem of claim 11, wherein the rotatable bracket is rotatable between avertical position for vertical welding, and a horizontal position foroverhead welding.